This procedure covers the replacement of both valve cover gaskets on the 3.5L EcoBoost V6 engine, including removal of necessary components and proper sealing techniques to prevent oil leaks.

Warnings

Tools required

Parts

• Left valve cover gasket × 1 — Use OEM Ford specification
• Right valve cover gasket × 1 — Use OEM Ford specification
• Spark plug tube seals (set of 6) × 1 — Use OEM Ford specification
• Ignition coil boots (if damaged) × 6 — Inspect during removal

Preparation

1. Park vehicle on level surface and allow engine to cool completely (minimum 2 hours)
2. Disconnect negative battery terminal and wait 5 minutes
3. Remove engine cover by lifting up on front tabs and pulling forward
4. Clean the valve cover area with degreaser to prevent debris from entering engine during service
5. Take photos of electrical connector routing and component positions for reassembly reference

Procedure

1. 1

   Remove air intake system components
   Disconnect the intake air temperature sensor and mass airflow sensor electrical connectors. Loosen the clamps on the intake tube and remove the air intake tube assembly from the throttle body to the air filter box. Remove the air filter box if needed for additional access to the right valve cover.
2. 2

   Disconnect electrical connectors
   Locate and disconnect all electrical connectors on top of the valve covers. This includes the 6 ignition coil connectors (3 per side), any cam position sensors, and any other harness connectors interfering with valve cover removal. Press release tabs and pull connectors straight off to avoid damage.
3. 3

   Remove ignition coils
   Remove the 10mm bolt from each ignition coil (6 total). Carefully twist and pull each ignition coil straight up from the spark plug tube. If stuck, use an ignition coil puller tool or carefully work the coil back and forth while pulling upward. Inspect the coil boots for damage or oil contamination and replace if necessary.
   Torque spec

   Ignition Coil Bolts8 Nm (6 lb-ft)
4. 4

   Remove PCV hoses and breather tubes
   Disconnect the PCV hose from the driver side valve cover and the crankcase breather tube from the passenger side valve cover. These are push-fit connections; squeeze the retaining clips and pull straight off. Note routing for reinstallation.
5. 5

   Remove wiring harness brackets
   Unbolt any wiring harness brackets or clips mounted to the valve covers. Typically there are 2-3 brackets per side that must be removed. Carefully move the harness aside to provide clear access to all valve cover bolts.
6. 6

   Remove right (passenger side) valve cover
   Remove all 11 valve cover bolts in reverse of tightening sequence (work from outside to inside). Gently tap the valve cover with a rubber mallet if stuck, then lift it straight up and off the cylinder head. Be careful not to drop bolts or debris into the engine. Inspect the mating surface on the cylinder head for damage.
   ⚠Do not pry between the valve cover and cylinder head as this will damage the sealing surfaces.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
7. 7

   Remove left (driver side) valve cover
   Remove all 11 valve cover bolts in reverse of tightening sequence. The driver side may require additional clearance; you may need to move power steering lines or other components slightly. Gently tap the valve cover with a rubber mallet if stuck, then lift straight up and off the cylinder head.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
8. 8

   Remove old gaskets and spark plug tube seals
   Carefully remove the old valve cover gaskets from both covers and cylinder heads. Use plastic scrapers only to avoid damaging aluminum surfaces. Remove all 6 old spark plug tube seals from the cylinder heads using needle-nose pliers. Clean all gasket surfaces thoroughly with brake cleaner and shop towels until completely free of old gasket material and oil residue.
   ⚠Inspect cylinder heads for any signs of warping or damage. Minor scratches are acceptable, but deep gouges may prevent proper sealing.
9. 9

   Install new spark plug tube seals
   Lightly lubricate new spark plug tube seals with clean engine oil. Press the new seals into the cylinder head recesses by hand, ensuring they are fully seated and flush with the head surface. Use a socket that matches the outer diameter of the seal to press them in evenly if needed. Verify all 6 seals are properly installed before proceeding.
   Torque spec

   Spark Plug Tube Seals0 Nm (0 lb-ft)
10. 10

    Install new valve cover gaskets
    Position the new valve cover gaskets into the grooves on both valve covers. Ensure gaskets are fully seated in the channels with no twists or folds. The gaskets should have integrated grommets that hold them in place. Do not use any sealant or adhesive unless specifically required by the gasket manufacturer.
11. 11

    Install left valve cover
    Carefully position the left valve cover onto the cylinder head, ensuring the gasket stays in place and the spark plug tubes align properly. Hand-thread all 11 valve cover bolts. Tighten bolts in sequence (center to outside pattern) to 10 Nm (7 lb-ft). Do not overtighten as this can distort the cover and cause leaks.
    ⚠Follow proper tightening sequence from center outward to ensure even gasket compression and prevent warping.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
12. 12

    Install right valve cover
    Carefully position the right valve cover onto the cylinder head, ensuring the gasket stays in place and the spark plug tubes align properly. Hand-thread all 11 valve cover bolts. Tighten bolts in sequence (center to outside pattern) to 10 Nm (7 lb-ft). Verify all bolts are properly torqued.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
13. 13

    Reinstall ignition coils
    Apply a small amount of dielectric grease to the inside of each ignition coil boot. Carefully align each ignition coil with its spark plug tube and press down firmly until fully seated. Install and tighten the ignition coil bolts to 8 Nm (6 lb-ft). Reconnect all 6 ignition coil electrical connectors.
    Torque spec

    Ignition Coil Bolts8 Nm (6 lb-ft)
14. 14

    Reinstall remaining components
    Reinstall all wiring harness brackets and clips to the valve covers. Reconnect the PCV hose to the driver side valve cover and the crankcase breather tube to the passenger side valve cover. Ensure all connections are secure and properly seated. Reconnect any remaining electrical connectors that were disconnected.
15. 15

    Reinstall air intake system
    Reinstall the air filter box if removed. Reinstall the intake air tube, ensuring all clamps are tight and connections are secure. Reconnect the mass airflow sensor and intake air temperature sensor electrical connectors. Reinstall the engine cover by aligning rear tabs first, then pressing down on front tabs until they click into place. Reconnect the negative battery terminal.

Reassembly

1. Double-check that all electrical connectors are properly seated and locked
2. Verify all hoses and tubes are connected and routed correctly per photos taken during disassembly
3. Ensure no tools or parts were left in the engine bay
4. Verify valve cover bolts were torqued in proper sequence to prevent leaks

Verification

• Start the engine and listen for any unusual noises or misfires
• Allow engine to idle for 5 minutes and check for oil leaks around both valve covers
• Rev engine to 2500 RPM briefly and recheck for leaks
• Check for any vacuum leaks by listening for hissing sounds around PCV and breather connections
• Verify engine runs smoothly with no check engine light or misfire codes
• After test drive, recheck valve cover area for any signs of oil seepage and retorque if necessary after engine cools

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